Composite panel usable for forming a surface

ABSTRACT

Embodiments of the disclosure pertain to a panel usable for forming a surface, the panel having an at least one finish element; a backing material; and a polyurethane material cured between the at least one finish element and the backing material. Upon curing, the polyurethane material forms a structural substrate having a first side and a second side. Upon curing, the backing material is adhesively bonded to the first side. Also upon curing, the at least one finish element is adhesively bonded to the second side.

CROSS-REFERENCE TO RELATED APPLICATIONS AND INCORPORATION BY REFERENCE

This application is a continuation of U.S. Non-Provisional patentapplication Ser. No. 14/973,776, filed Dec. 18, 2015, which is adivisional of U.S. patent application Ser. No. 13/741,029, filed on Jan.14, 2013, now U.S. Pat. No. 9,303,403, which is a continuation-in-partof U.S. patent application Ser. No. 12/459,156, filed Jun. 26, 2009, nowU.S. Pat. No. 8,353,144. The entirety of each application isincorporated herein by reference for all purposes.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

BACKGROUND Field

Embodiments usable within the scope of the present disclosure relate,generally, to manufactured panels used in the construction of buildingsand building components, namely, in the construction of interior and/orexterior walls, floors, ceilings, roofing, or any other surface. Morespecifically, embodiments usable within the scope of the presentdisclosure relate to pre-fabricated panels having exterior elementsthereon to provide the panels with a desired appearance, such elementsable to be lighter and thinner than conventional masonry counterpartsdue to the structural characteristics of the panel. Embodiments of thepresent disclosure also relate to manufacturing processes usable tocreate such panels.

SUMMARY

Embodiments of the disclosure pertain to a composite panel usable forforming a surface that may include one or more of: an at least onefinish element; a backing material, the backing material configured toprovide the panel with a reduced thickness, a reduced weight, orcombinations thereof; and a polyurethane material cured between the atleast one finish element and the backing material.

Upon curing, the polyurethane material may form a structural substratehaving a first side and a second side. Upon curing, the backing materialmay be adhesively bonded to the first side. Upon curing, the at leastone finish element may be adhesively bonded to the second side.

The composite panel may include a particulate material disposedproximate to the first side of the structural substrate, and between afirst finish element and a second element. The structural substrate maybond the particulate material to the at least one finish element and thebacking material. At least a part of a layer of structural substrate mayat least partially occupy interstices between particles of theparticulate material. In aspects, the particulate material may include abinder composition.

The at least one finish element may include magnesium oxide. The atleast one finish element may be configured to further provide the panelwith a reduced thickness, a reduced weight, or combinations thereof.

The at least one finish element may include a body having an interiorsurface bonded to the structural substrate. The at least one finishelement may include an exterior surface that may have a coating thatincludes cement, clay, and/or an aggregate. The coating may provide theat least one finish element with an appearance of a natural clay brick.

In aspects, the clay may include clay dust. In aspects, the aggregatemay include sand.

The composite panel may be configured for installation on at least oneof an exterior wall of a building, an interior wall of a building, afloor, a ceiling, a roof, a counter, a backsplash, and combinationsthereof.

Other embodiments of the disclosure pertain to a composite panel usablefor forming a surface that may include one or more of a first finishelement and a second finish element; a backing material; a curedpolyurethane material having a first side and a second side, the curedpolyurethane material being cured between the first finish element andthe backing material; and a particulate material disposed proximate tothe first side, and between the first finish element and the secondfinish element.

The backing material may be adhesively bonded to the first side. Thefirst finish element may be adhesively bonded to the second side.

The cured polyurethane material may bond the particulate material to thefirst finish element. In aspects, the cured polyurethane material may atleast partially occupy interstices between particles of the particulatematerial.

The particulate material may include a binder composition.

At least one of the first finish element and the second finish elementmay include magnesium oxide. At least one of the first finish elementand the second finish element may be configured to further provide thepanel with a reduced thickness, a reduced weight, or combinationsthereof.

The first finish element may include a body having an interior surfacebonded to the structural substrate. The first finish element may includean exterior surface. The exterior surface may include a coating havingone or more of cement, clay, and/or an aggregate. In aspects, thecoating may provide the at least one finish element with an appearanceof a natural clay brick. Clay may include clay dust. Aggregate mayinclude sand.

The composite panel may be configured for installation on at least oneof an exterior wall of a building, an interior wall of a building, afloor, a ceiling, a roof, a counter, a backsplash, and combinationsthereof.

These and other embodiments, features and advantages will be apparent inthe following detailed description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the detailed description of various embodiments of the presentinvention presented below, reference is made to the accompanyingdrawings, in which:

FIG. 1 is an elevational view illustrating an embodiment of panelsusable within the scope of the present disclosure, installed on aframework of a building structure;

FIG. 2 is a vertical sectional view taken along line 2-2 of FIG. 1;

FIG. 3 is a horizontal sectional view taken along line 3-3 of FIG. 1;

FIG. 4 is an isometric view of illustration showing a portion of anembodiment of a panel usable within the scope of the present disclosure;

FIG. 5 is an exploded isometric view illustrating one possible method ofmanufacture for a panel using a machine;

FIG. 6 is an isometric illustration showing a part of a masonry elementalignment jig having alignment pins usable with an embodiment of amethod for manufacturing panels;

FIG. 6A is an isometric illustration showing an association of thealignment pins of FIG. 6 with a finish element;

FIG. 6B is a partial isometric illustration of an alignment jig havingridges usable with an embodiment of a method for manufacturing panels;

FIG. 7 is an isometric illustration of a screed member having groutholes or slots usable with an embodiment of a method for manufacturingpanels;

FIG. 7A is a partial plan view showing a portion of the screed member ofFIG. 7;

FIG. 8 is an exploded isometric illustration showing an open-cellpolymer foam sponge panel with a rigid backing positioned above amasonry element alignment jig, usable with an embodiment of a method formanufacturing panels;

FIG. 9 is an exploded isometric illustration showing a masonry elementalignment jig and a foam substrate applicator for mixing and applying asubstrate of polymer foam binding material to the jig, usable with anembodiment of a method for manufacturing panels;

FIG. 10 is a schematic illustration showing one possible embodiment ofan automated manufacturing process and system usable to manufacture apanel usable within the scope of the present disclosure;

FIG. 11 is a vertical sectional view showing a conventional exteriorwall construction;

FIG. 12 is a vertical sectional view showing an embodiment of a panelusable within the scope of the present disclosure;

FIG. 13A shows an isometric view of an embodiment of a finish elementstorage receptacle usable in connection with an embodiment of a methodfor manufacturing a panel;

FIG. 13B shows a diagrammatic side sectional view of the storagereceptacle of FIG. 13A;

FIG. 14A depicts an isometric view of an embodiment of a frame usablewith a vacuum apparatus in connection with an embodiment of a method formanufacturing a panel;

FIG. 14B depicts a top plan view of the frame of FIG. 14A, withstand-off members placed thereon;

FIG. 14C depicts a diagrammatic side sectional view of the frame of FIG.14B, with an overlaying screen placed thereon;

FIG. 15A depicts a diagrammatic side view of a frame usable with avacuum apparatus in association with a finish element storage receptaclefor use with an embodiment of a method for manufacturing a panel;

FIG. 15B depicts the frame of FIG. 15A in association with panel frameelements for use with an embodiment of a method for manufacturing apanel;

FIG. 15C depicts the frame of FIG. 15B in association with a particulatematerial storage receptacle for use with an embodiment of a method formanufacturing a panel;

FIG. 15D depicts the frame of FIG. 15C in association with a mold foruse with an embodiment of a method for manufacturing a panel.

FIG. 15E depicts the mold of FIG. 15D after deposition of panelcomponents therein for use with an embodiment of a method formanufacturing a panel.

Embodiments of the present invention are described below with referenceto the listed Figures.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Before explaining selected embodiments of the present invention indetail, it is to be understood that the present invention is not limitedto the particular embodiments described herein and that the presentinvention can be practiced or carried out in various ways.

Referring now to FIG. 1, a plurality of panels 10, usable within thescope of the present disclosure are shown secured to framework members12 to form an exterior wall of a building. For illustrative purposes,FIG. 1 depicts only portions of the framework of the building structure.

While FIG. 1 depicts panels that are usable to form the finish orexternal facade of the exterior walls of a building, it should beunderstood that panels could be provided with materials suitable for usewith interior walls of buildings, floors, ceilings, roofs, counters,backsplashes, or any other interior or exterior surface. Embodiments ofthe present panel can be weather resistant and serve as moisturebarriers, thus providing resiliency to the exterior of a building, whileenabling any interior wall of a building that might be subject tocontact by water, such as bathrooms, kitchens, laundry rooms, etc. to beprovided with moisture barriers to minimize potential damage by water,and to promote efficient and effective cleaning of the walls.

For example, embodied panels can be provided with various types of waterresistant surface finish materials, such as ceramic tile, glass orpolymer tile, and polymer wall surfaces, for example. Embodiments ofpanels usable within the scope of the present disclosure can have athermal insulating quality that exceeds the thermal insulatingcharacteristics of conventional masonry walls, can have a thinnerprofile than conventional walls, and can be installed in significantlyless time when compared to the installation of the various layers(substrate, vapor barrier, insulation, brick, mortar, etc.) of a wallrequired by building codes and conventional methods. Due to thelightweight and/or thinner nature of various embodied panels, thefoundation of a building structure can also be of lighter weightconstruction (thus providing weight and cost savings), because thefoundation would not be required to support the weight of a typicalbrick and mortar wall.

The term “masonry” as used herein is intended to encompass a wide rangeof materials, including, without limitation, natural and manufacturedstone materials, artificial stone materials, and special effect finishor facade materials usable to provide visible wall surfaces with adesired appearance. The terms “brick members”, “thin bricks”, “finishelements” and “thin masonry elements,” as used herein, are intended toencompass any of a number of thin masonry or masonry-like members ofrectangular, square, round, ovoid, triangular or other suitableconfiguration.

For example, FIG. 1 depicts panels having external finish elements,e.g., masonry or facade members, thereon to provide the panels with theexternal appearance of the conventional bricks of a masonry or masonryveneer wall structure. However any natural, manufactured, or artificialveneer or element can be provided to the panels without departing fromthe scope of the present disclosure.

Where natural or artificial stone is used as a finish material it can beprovided in a “repeating pattern” such that individual finish elementscan be positioned at specifically designed locations, e.g., within ajig, magazine, or similar frame or retention element, during panelmanufacture. The term “facade members” is intended to include a widevariety of possible surface materials, such as ceramic tile, compositematerials including wood, various polymer materials, glass, rubber likematerials, etc.

The panels 10 of FIGS. 1-3 are depicted as composite panels having awood or masonry sheathing or backing panel 14, that is embedded withinor in fixed assembly with a moisture resistant panel substrate 16composed of polyurethane, polyurethane foam or other similar single ormulti-component polymeric materials that form a moisture barrier.Embodied panels can thereby have flexibility similar to that of plywoodor similar materials, such that a wall or other surface of a buildingstructure, formed by the panels, can flex or move slightly in responseto naturally occurring forces without fracturing or cracking any portionof the panels, which is a common shortcoming of conventional structuralmaterials.

The substrate material 16 is depicted having a rectangular configurationand defines a rectangular surround structure 18, having edges 19 thatdefine the top, bottom and sides of the depicted panel. The depictedpanel can be provided in 48″×96″ or 48″×32⅝″ sizes, to facilitatefitting within the on-center stud spacing of a conventional buildingframework. However, the panels may be of larger or smaller dimensiondepending on the size and/or orientation of the panels, the purpose ofthe panel and the structure with which the panels are to be used, and/oron the preferences of the designer, contractor, and/or other personnel.

As shown in FIG. 2, the surround structure 18 can include splineopenings, channels or receptacles 20, within which spline members 22 canbe received to facilitate edge to edge alignment of adjacent panels. Inan embodiment, one side of each panel can include a spline slot orchannel, while the opposing side of an adjacent panel can include aspline member projecting therefrom for insertion into the channel, toensure that the edges 19 of adjacent panels are properly aligned. Properalignment of panels can ensure the proper appearance of an externalfacade, e.g., panels having thin brick, stone, and/or masonry membershaving the appearance of a wall.

However, in other embodiments, each of the surround portions of a panelstructure can include spline slots, while spline members can bepositioned within adjacent spline slots after construction of the panels(e.g., during installation in the field). In addition to maintainingeach of the top, bottom and side edges of adjacent panels in alignment,the splines also assist in providing a weather-tight closure of jointsbetween the edges of adjacent panels to minimize the potential foringress of water and/or air. In an embodiment, closure and/or sealingbetween panels can be enhanced by application of interlocking flashingstrips 29 (shown in FIG. 1), which can include strips of metal, polymeror any other suitable flashing material, positioned over the jointsbetween edges of adjacent panels.

While FIG. 1 depicts only a single flashing strip 29 for illustrativepurposes, it should be understood that any number of panel joints 28 canbe covered by flashing to improve water resistance of a resulting wall.To facilitate installation of the flashing strips, the lateral groutlines of each panel can be limited in length, such that they do notextend completely to the side edges of the panels, as shown in FIG. 4.

Alternatively or additionally, the ends of the grout lines can beremoved to provide flat edge surfaces for mounting of the flashing. Theflashing strips 29 may be secured in place by screws, nails, rivets, orany other type of retainer member, fastener, and/or bonding material oradhesive. Sealing of the panel joints 28 can further be enhanced byapplication of a moisture impervious layer of silicon caulking or othersealing material. The flashing strips 29 may be applied over the jointcaulking material if desired. The moisture impervious layer willsubsequently cure to a durable form. In an embodiment, the closurestrips and joint sealant can be covered by finish elements such that theclosure strips and sealant are not visible in a completed structure.

A plurality of finish elements 24, which are depicted as masonry ormasonry-like facade elements in FIGS. 1 and 4, are shown placed in adesired pattern on each panel. Finish elements 24 can be placed in thedesired pattern within a mold, and a dry pulverulent grout/particulatematerial 26 can be placed and/or compacted within grout spaces betweenthe finish elements. The finish elements 24 can include a wide varietyof surface materials, such as ceramic tiles, natural or artificialstones, or other surfaces suitable for use with interior or exteriorwalls, flooring, ceilings, counters, backsplashes, and roofs. In anembodiment, the finish elements 24 can include a porous material,defining minute interstices into which uncured liquid polymeric materialcan penetrate during the manufacturing process to facilitate retentionof the finish elements within the body of the panel.

The pulverulent/particulate material 26 is shown within the gaps orspaces between the top, bottom and side edges of adjacent finishelements, and can be compacted within the spaces prior to application ofthe substrate. In an embodiment, the particulate material can be locatedonly in the spaces between the finish elements, and is not placedbeneath the finish elements to secure the finish elements to the panelstructure. The polymeric/substrate component of the composite panelassembly serves to affix the finish elements to the panel, such that thepulverulent/particulate material is not required to function asconventional grout or mortar.

Even distribution and compaction of the grout material within the groutspaces can be accomplished by subjecting the grout to mechanicalpressure, such as by use of a press mechanism (e.g., a resilient pad ofopen cell polymeric foam or similar resilient material attached to apress plate, which can be deformed into the grout spaces by the force ofthe press). The particulate material can include a binder compositionmixed therein, such that arranged/compacted material will retain itscompacted/arranged state during the panel manufacturing process.

The finish elements and particulate/pulverulent material can be securedto the panel structure 16 by the adhesion that occurs as an uncuredliquid polymeric foam mixture or similar suitable substrate is sprayed,poured, and/or otherwise placed in association with the back surfaces ofthe finish elements, after positioning the finish elements in a desiredarrangement within a mold. The polymer or polymeric foam substrateserves to fix the finish elements to the panel structure.

During manufacture, the substrate can be confined within a mold in itsuncured state, and subjected to the mechanical pressure (e.g., via apress), causing the polymeric foam to assume the configuration of anintegral polymeric substrate covering substantially the entire rearsurface of the panel, thereby forming a moisture resistant and thermalinsulating layer. The mold can be shaped to cause the polymeric foamsubstrate to define a surround or border structure of the panel (e.g. bypermitting the substrate to flow around the edges of other panelcomponents prior to curing).

In an embodiment, the border can have a rectangular shape, but it shouldbe understood that any shape and/or dimension can be achieved dependingon the configuration of the mold. In an alternative embodiment, one ormore finish elements can be secured to the substrate using a bondingagent (e.g., cement, adhesive) or any other means for mechanicalretention. FIG. 1 depicts a plurality of “missing brick” and/or“leave-out” spaces 30, located at the edges of adjacent panels, wheresuch alternative methods can be used to apply finish elements to thepanel.

As described above, FIGS. 1-3 depict the finish elements 24 as thinbrick or brick-like masonry members, such that a finished wall formedfrom the depicted panels will have the appearance and serviceability ofa conventional brick and mortar wall. It should be understood, however,that the finish elements 24 can include any type of surface, includinggenerally thin and/or flat natural or artificial stones, or any othertype of desired surface (granite, tile, wood, laminate, etc.).

Materials other than masonry or stone members may also be used to formthe exterior finish or facade of the pre-manufactured constructionpanels so that the resulting wall structure may have any desiredappearance. When stones or similar irregularly-shaped elements are used,the elements can be positioned to accommodate a repeating facadepattern. Such an arrangement can permit the finish elements to beretained in a jig having the desired pattern during panel manufacture.In an embodiment, jigs and/or finish elements can be designed to resultin uneven positioning of the face surfaces of the finish elements, suchas when it is desired to provide a wall having uneven surfaces to mimica conventional stone wall.

As noted above and shown in FIGS. 1 and 4, abutting side edges 19 ofadjacent panels fit together to form edge joints 28. The pattern of thefinish elements 24 along the sides of the panels is shown terminatingprior to the edge of each panel (e.g., in a spaced and/or set backrelation from the side edges) to define “missing brick” spaces 30. Itshould be noted that sites for receiving finish elements located at theedges of adjacent panels can bridge/extend across the edge joints 28.

For example, FIG. 1 shows the grout lines above and below the missingbrick spaces extending to the side edges of the panel to define a spacewhere a “missing” finish element can be added. In the case ofrectangular masonry elements, such as thin bricks, the filler bricks canbe secured across two abutting panels, such that the joint between thepanels is not apparent. The size and arrangement of the finish elements24 and missing brick spaces 30 can be selected such that one or multiplefinish elements can be placed in the spaces 30, or a fillerassembly/material can be applied.

With reference to FIG. 4, an embodiment of a panel 10 usable within thescope of the present disclosure is shown in greater detail, in asubstantially horizontal position, suitable for manufacture (asdescribed below in connection with FIGS. 8 and 9. As described above, asheathing or backing panel 14, which can be composed of wood, masonry,OSB, polymer or any other generally durable material usable as sheathingmaterial, forms an interior surface portion of the panel structure.

A moisture impervious or resistant multi-function polymeric substrate16, which can be composed of polyurethane, polyurethane foam or any oneof a number of other suitable single or multi-component polymericmaterials, is integrated with the sheathing or backing panel 14, and inthe depicted embodiment, provides a generally rectangular surroundstructure 18 that is integral therewith and encompasses the edges 25 ofthe sheathing panel 14. The surround structure 18 is shown having arectangular configuration (e.g., 4′×8′), defining substantially straightedges 19 at the top and bottom sides of the panel. The polymericsubstrate 16 can provide the panels with moisture resistance and thermalinsulation characteristics, and can materially enhance the structuralintegrity of the panels.

Independent of the shape, configuration, and dimensions depicted in FIG.4, it should be understood that embodied panels may be of any size,shape, and configuration able to be secured to an underlying buildingstructure (e.g. framework members), and/or that is able to accommodatedesired finish elements. On one or both of the sides of the panelstructure, and on the upper or lower edge, the surround structure 18 caninclude spline slots or channels 22 for receiving spline members 22,able to be received in channels of adjacent panels to facilitatealignment. The spline members 22 can enhance the structural integrity ofassembled panels and facilitate closure of a joint 28 between adjacentpanels to reduce water and/or air ingress.

As shown, for example, in FIG. 2, the finish elements 24 can be placedin a desired relationship, (e.g. a spaced relationship), and at leastpartially embedded within and/or fixed to the polymeric substrate 16.The finish elements 24 can be separated by grout lines 26 to provide,e.g., the appearance and function of a conventional brick or brickveneer wall structure. At each end of the panel structure, empty spaces30, as shown in FIGS. 1 and 4, are defined, so that side edges 19 of thepanels can be straight, independent of the dimensions and/or type offinish elements used; however, it should be understood that such spacesmay not be necessary in embodiments where finish elements can bearranged in a configuration where one or more elements would not extendbeyond the edges of a panel, and/or when types of finish elements ableto be shaped, cut, and/or omitted, without hindering the overallfunction or appearance of the panel are used.

After the panels have been secured to the framework members 12, e.g. ofa wall structure, such as by screws or any other suitable fasteners,adhesives, bonding agents, etc., any empty spaces 30 can be filled withadditional finish elements and/or by a filler assembly, e.g., to bridgeadjacent panel joints 28. Any number of additional panels can be securedto a wall/surface structure to expand the structure in a vertical orhorizontal/lateral direction. Particulate and/or spacing material can besprayed or otherwise applied in the spaces between the finish elementsto both provide a desired spacing and appearance, and to cover anydamage that could be caused by screws and/or other fasteners that areapplied to secure the panels.

In an embodiment, any manner of adhesive material can be used to attachfinish elements or other materials to the empty spaces 30, while siliconand/or other suitable caulking materials (e.g. a two-component epoxy)can be applied in the grout space adjacent each empty space. Siliconand/or caulking materials can also function as a surface adhesive tobond particulate material between the finish elements, and to bondfinish elements placed in the empty spaces 30. The caulking material canalso assist the sealing capability of the splines at the edges of thepanels. While the silicon or other caulking material is in its uncuredstate, particulate materials can be applied to the spaces between finishelements, where it can become embedded in and/or adhered to the caulkingmaterial.

As such, the depicted panels can be provided with the appearance of aconventional masonry wall structure, while the joints 28 betweenadjacent panels are not visible in a completed construction.Installation of conventional brick facade materials requires a cleaningstep to remove brick and mortar dust from the exterior show surface ofthe brick facade, e.g., using an acid solution. Embodiments of thepresent panels do not require subsequent cleaning, further conservingtime and expense when compared to conventional materials and methods. Inother embodiments, finish elements can extend beyond the edge of onepanel, for receipt in an adjacent empty space of an adjacent panel,rather than installing such finish elements in the field.

In one possible embodiment, finish elements can be formed fromexceptionally lightweight materials. For example, magnesium oxidematerials, such as those available from Jet Products, LLC, are typicallyavailable in the form of 0.5″×4 8″×96″ or 0.25″×24″×48″ boards. Suchboards are typically brittle when used in such large sizes, and as such,are available with fiberglass reinforcement materials. However, smallerpanels of magnesium oxide, e.g., 2.625″×7.625″ rectangles, sizedsimilarly to brick veneer elements, do not suffer from the samedrawbacks and are as durable, if not more so, than conventional brickand/or masonry veneer materials and facade elements. Magnesium oxidematerials are significantly lighter than other masonry facade materials,and can be much thinner than other masonry counterparts, reducing thetime, weight, and expense required to construct a panel using suchelements.

It is noted that magnesium oxide materials are normally extremelysmooth, and white in color, and as such, would normally be unsuitablefor use as aesthetic substitutes for brick veneer. However, in anembodiment, finish elements of magnesium oxide can be ground on at leastone surface thereof to provide a surface texture that mimics the textureof a natural clay brick, dipped into an exterior-grade concrete stain,then dipped into a composition that includes Portland cement, magnesiumcement, clay dust, and a light aggregate (e.g., sand). While normalmethods of coloration are typically not effective for staining,coloring, and/or changing the appearance of magnesium oxide materials, acomposition including such components can provide magnesium oxide finishelements having at ground/textured surface with a color similar to thatof natural brick.

Magnesium oxide materials can also be used as backing/sheathing layersin embodiments of the present panel. For example, a magnesium oxidepanel (e.g., a 0.25″×24″×48″ board thereof) can have an adhesivecompound applied to its surface, while finish elements (such2.625″×7.625″ as magnesium oxide elements, as described above) can bebonded thereto with a gap (e.g., 0.375 inches) between the elements tosimulate the appearance of a brick wall. A particulate mixture can beapplied to the spaces between the finish elements to complete theappearance of the wall. As the adhesive cures, it can adhere the finishelements and particulate material to the backing panel. Finish elementsat the edges of the panel can be allowed to extend past the edge thereof(e.g. 0.125 inches beyond the edge) to facilitate alignment withadjacent panels and to cover the gap between adjacent panels.

A completed panel of such construction has the appearance and feel of atypical masonry brick wall, but does not require the structural supportnormally associated with brick installation. Such panels are alsolightweight, fire resistant, and sound absorbing (acoustically soft.)The panel can be applied directly to open framing studs, an existingdrywall or wood surface, metal panels, or any other framework member,such as through use of drywall or deck screws, contact or wallboardadhesives, or other mechanical and/or adhesive means. While the panel isdescribed in the context for use in an exterior brick wall of astructure, it should be noted that such panels can be used with interiorwalls, floors, ceilings, roofs, counters, backsplashes, and any otherstructural surface.

Referring now to FIG. 5, an isometric view illustrating one embodimentof manufacturing panels usable within the scope of the presentdisclosure is shown. A manufacturing machine 32 having a productiontable 34, supported and stabilized by legs 36, defines a table top 38that serves as a substantially flat and horizontally oriented moldsupport member. The manufacturing machine 32 also includes a pressdevice 40 having a press support plate member 42 and a moveable platen44. The moveable platen can be driven by a motorized actuator 46, suchas a hydraulically energized ram or an electrically driven actuatormember, or any other suitable mechanism for driving the moveable platen44 downward to apply a desired mechanical force to a mold 51, that issituated on the press support plate member 42. One or more guide bars 48or similar members, extending through guide openings 50 in the edges ofthe press support plate member 42, can be used to guide the platen 44.

The manufacturing process can begin by placing a mold base 52, shown asa generally rectangular member, on the production table 34. The depictedmold base 52 defines a rectangular mold pocket, recess or receptacle 54therein having a bottom receptacle wall 56. The mold base 52 can becomposed of wood, metal or any of a number of suitable polymer materialsand/or composite materials. If desired, a mold composed of a suitablematerial, such as silicon, may be placed within the mold recess 54 toprovide location devices or geometry for precise location of finishelements within the mold.

In an embodiment, a finish element alignment jig 53, shown in FIGS. 6and 6A, can be placed in the mold recess or receptacle 54, the jigdefining multiple finish element sites 58 within the recess. Each of thedepicted finish element sites 58 can include spacers or similar meansfor facilitating precise location and alignment of the finish elements.Suitable means for finish element location, with respect to the bottomwall 56, can include locator pins 59 that extend upward from the jig 53,generally to a height less than the thickness of the finish elements. Inthe embodiment shown in FIGS. 6 and 6A, each of the finish element sites58 is defined by eight locator pins 59, two of which are positioned inaligning relation with each of the four corners of a finish element 24,as shown in FIG. 6A.

The locator pins 59 can position the finish elements 24 in accuratelyspaced relation with one another to define grout spaces therebetween andprevent the finish elements from shifting laterally during the panelmanufacturing process. This feature permits each finished compositeconstruction panel to have the resulting appearance of, for example, aportion of a brick and mortar wall, with the even spaces between thefinish elements serving to provide the appearance of the conventionalmortar joints.

When finish elements having irregular (e.g. non-rectangular) shapes areused, such as when attempting to replicate the appearance of a stonewall, the alignment members or pins of a specifically designed stonepositioning jig can be located according to a repeating patternutilizing specific shapes and dimensions of each element. The finishelements, can be placed “outer or front surface down” within the elementsites 58 defined by the locator elements or pins 59 of the alignment jig53, thus positioning the thin finish elements 24 in properly orientedand spaced relation with one another, independent of the specificdimensions of each finish element. The uneven face surface positioningof irregular elements, such as the stones of a stone wall, can bereplicated by the construction of the special jig or by the use ofsupport and/or positioning members within the mold or jig, orcombinations of these approaches.

In the alternative or in addition, location of the finish elements maybe achieved by providing alignment ridges 60 on the bottom wall 56 ofthe mold base 52, as shown in FIG. 6B, or by providing location geometryin a mold composed of silicon or another suitable flexible moldmaterial. The alignment ridges 60 permit secure and accurate positioningof each of the finish elements 24, enabling accurate spacingtherebetween. The alignment ridges 60 can also prevent lateral shiftingof the elements during the panel manufacturing process. Other means foraccurately locating finish elements with respect to a mold base can alsobe provided within the spirit and scope of the present disclosure.

FIG. 7 depicts a generally screed panel member 62, having a generallyrectangular shape, while FIG. 7A depicts a detailed view of a portionthereof. In use, the screed panel member 62 can be removably placedwithin the mold base 52, above the arranged finish elements 24. Thescreed panel member 62 defines a planar bottom surface 63 for engagementwith the inner or back faces of the finish elements, and is shown havinga plurality of slots 64 (e.g., holes for depositing particulate materialtherethrough) that are positioned in alignment with the grooves orspaces that are defined between adjacent finish elements, which aresupported by the jig 53 (shown in FIG. 6). The screed 64 can be alignedwith the spaces between the finish elements 24 using, for example,alignment pins projecting from the mold to engage correspondingalignment holes in the screed panel.

During panel manufacture, the machine 32 can be configured to preciselyposition the screed panel with respect to the mold. As such, theconfiguration of the slots 64 is such that dry pulverulent orparticulate material can be readily deposited into the spaces betweenfinish elements while the body of the screed prevents the passage ofsuch material to other parts of the mold and/or panel. The shapes of theslots 64 can determine the amount and specific location of theparticulate material. In an embodiment, the pulverulent/particulatematerial can include a binder composition that enables the material tobe compacted to an essentially solid, porous form, and to maintain itscompacted form as successive panel manufacturing process steps occur.

The planar surface 63 of the screed panel member 62 can engage and/orcover the surfaces of the finish elements to ensure that the backsurfaces thereof remain free of the particulate material depositedthrough the slots 64. In an embodiment, deposition of particulatematerial can be accomplished simply by applying the particulate materialto the upper surface of the screed member 62, then sweeping or wipingthe material through the slots 64, so that an essentially measuredquantity of particulate material falls into the spaces between finishelements. Alternatively, an application system may be provided fordirectly depositing material into the slots 64, so that very littleparticulate, if any, is permitted to contact the upper surface of thescreed panel member or the back surfaces of the finish elements.

After the grout deposit operation has been completed, the screed member62 can be removed from the mold so that loose dry pulverulent orparticulate material is present and substantially evenly distributedwithin the spaces 62 between the finish elements 24. As stated above,since portions of the screed member 62 cover the back faces of thefinish elements 24 during the deposit process, the back faces can remainsubstantially free of particulate.

With reference to FIG. 8, when it is desirable to subject the looseparticulate material to a desired compaction within the spaces betweenthe finish elements, to facilitate even distribution and properplacement thereof, a compressive force application mechanism 80 can beused. Compaction prepares the particulate material to receive an uncuredor substantially liquid polymeric material, such as mixed but uncuredurethane foam, so that the liquid polymeric material applied in asubsequent step penetrates to a desired depth within the material, butdoes not penetrate completely therethrough.

As such, a layer of the particulate material can be bonded or otherwisesecured to the polymeric substrate, such that the material becomessubstantially permanently fixed within the spaces between finishelements. By ensuring that the polymeric material does not fullypenetrate the particulate material, the polymeric material does notbecome exposed to view within the spaces, which could potentiallydetract from the desired ornamental appearance of the finished panel.

The depicted force application mechanism 80 includes an actuator andactuator control system 82, such as a pneumatic or hydraulic actuator,having a vertically moveable actuator member 84 to which a stiffrectangular backing panel member 78 is secured. A rectangular panel 76including a soft and/or deformable material, such as an open cell foammaterial, is shown secured to the lower surface of the backing panelmember 78, thereby providing a soft body of material that can engage theback surfaces of the finish elements and be deformed into the spaces 69when compressive force is applied to the stiff backing member 78.

While FIG. 8 shows rectangular components, it should be understood thata compressive force mechanism having any desired shape and/or dimensionscould be used to compress all or a portion of the assembled panelelements. Additionally, while FIG. 8 depicts a mechanism oriented toapply force in a downward/vertical direction, other orientations ofpanel elements and mechanisms could be used without departing from thescope of the present disclosure. When the actuator mechanism 82 isenergized to provide force (e.g. in a downward direction), the actuatormember 84 will drive the backing member and panel 76 into contact withthe back surfaces of the finish elements 24.

Further movement of the backing member 78 and panel 76 can conform thematerial of the panel to the configurations of the finish elements 24,such that the material of the panel 76 enters the spaces 69 betweenfinish elements. Portions of the material that contact the particulatematter within the spaces 69, previously deposited loosely through theslots of the screed member, as described above, can cause evendistribution and compaction of the particulate material. As theparticulate material is compacted, a binder composition, mixedtherewith, can cause the particulate material to be compacted into asubstantially rigid, porous form, such that the particulate materialremains in place within the spaces 69 throughout the panel manufacturingprocess.

The porous nature of the compacted particulate material definesinterstices into which uncured polymeric foam material can migrate asthe mold and panel assembly is later subjected to the mechanicalpressure of a press. The compacted nature of the particulate material,the consistency and applied volume of the liquid polymeric substratematerial, and the pressure that is applied by the press, can be selectedto ensure that the polymeric material does not penetrate completelythrough the grout material to the front surface thereof, where it wouldbe visible. The cured polymeric material can provide support for theparticulate material within the spaces 69, while further providing thematerial with the appearance of a conventional mortar joint for a brickor other masonry wall, or any other desired appearance.

It should be noted that FIG. 8 represents a manufacturing step that canbe a part of an automated panel manufacturing system, whereby two ormore construction panels may be actively engaged in the manufacturingprocess at any point in time. This feature is discussed in greaterdetail below in conjunction with multiple manufacturing illustrated inFIG. 10.

After completion of the grout compaction operation, the actuatormechanism 82 can be energized to move the backing member 78 and panel 76away from the assembled panel elements (e.g. upwardly and/or laterally).The mold base or jig 52, with finish elements 24 and compactedparticulate material 26 can be subjected to subsequent manufacturingsteps, as illustrated in FIGS. 9 and 10. Subsequent steps can beperformed with the mold base 52 remaining stationary, or the mold basecan be moved to subsequent locations (e.g., manufacturing stations),such as described below with reference to FIG. 10.

FIG. 9 depicts a polymer foam applicator 68, associated with a polymerfoam mixing and supply system 66, which is usable to apply a contiguoussubstrate layer to the back face 71 of the assembled panel components.For example, the polymer foam applicator 68 can be moved relative to theback face 71 of the panel elements, and/or the mold base or jigcontaining the panel elements can be moved relative to the applicator68. The polymeric foam substrate 16 can provide the resulting panel withmechanical structure, a thermal insulating quality, and can also serveto provide a moisture and air barrier to minimize the potential forpassage and/or wicking of water and/or air through the panel.

While the use of a two component polymeric material, such aspolyurethane foam material, is specifically referenced, it should beunderstood that this is one illustrative example of a usable substratematerial, and that any polymeric or other type of material havingsimilar qualities can be used, including, without limitation, anymaterial that can set and/or cure, such as polyurea, or light- orthermally-activated, or chemically-catalyzed polymers.

Returning to FIG. 5, after the polyermic substrate 16 has been applied,an upper jig or mold lid 70 can then be brought into association withthe lower jig or mold base 52. A sheathing or backing panel 14, as shownin FIGS. 2-5, can be placed behind the substrate layer to add materialstiffness and structural integrity to the finished panel 10. The backingpanel 14 can be sufficiently flexible to provide the finished panel withflexibility during installation, prolonged usable life, and resistanceto stress and cracking. In one embodiment, the backing panel 14 can becomposed of oriented strand board “OSB”, a cement-containing panel orsheet, a polymer or polymeric composite, plywood, or any of a number ofother suitable rectangular panel sheet materials.

In other embodiments, the sheathing or backing panel 14 can includemagnesium oxide, as described above. In an embodiment, the backing panel14 can have a porous surface and/or a surface containing microscopicirregularities for facilitating bonding between the panel 14 and thepolymeric foam substrate. When wood or a similar material is utilized toform a sheathing or backing panel, the material may treated to enhancethe water-resistant character thereof and resist the tendency of variouswood or board materials to become warped by excess moisture. In anembodiment, only the exterior or facade surfaces of the finished panelcould be water resistant, while use of untreated wood or other similarmaterials as the backing substrate, that faces the interior of astructure, may be unlikely to cause damage due to the minimizedpotential for ingress of moisture through the exterior of the completedpanel.

During panel manufacture, as shown in the exploded isometricillustration of FIG. 9, the sheathing panel 14 can be positioned withina recess or pocket 72 within the upper jig lid 70, indicated by brokenlines at 74. As the upper jig lid 70 is positioned in association withthe jig or mold base 52, the sheathing substrate 14 can thereby contactthe uncured polymeric foam material that has been deposited on the backface of finish elements and particulate material. Association of theupper jig lid 70 with the mold base 52 can thereby accurately positionthe backing panel substrate 14 with the remainder of the panel elements,allowing the polymeric substrate to bond with the packing panel in amanner that will avoid de-lamination over time.

Once the upper jig lid 70 is lowered into association with the mold base52, the jig, mold, and/or upper jig lid can be subjected to mechanicalcompression, such as by means of a press, for a sufficient period oftime for the sheathing substrate 14 to become bonded to the polymericsubstrate, for pressure induced penetration of the polymer into theparticulate material, and for any small spaces that might exist withinthe mold to be filled with the polymeric material. In embodiments wherepolymer foam is used, expansion thereof will tend to fill the mold andgenerate internal pressure that enhances the density of the curedpolymeric foam.

Additionally, the mechanical compression, together with theconfiguration of the mold base, can prevent deformation of the panelduring curing of the polymeric material. Pressure-induced compression ofthe polymeric foam material during the manufacturing process can causethe polymeric foam material to produce the desired density to enhancethe moisture proofing and structural integrity of the completed panels.The pressure can also enhance the bond established between thesubstrates and components. When the mechanical compression is released,the completed panel can naturally maintain its flat configuration. Thus,when the construction panel is subsequently installed. e.g., to verticalcomponents of a building framework, such as wall studs, or othergenerally straight and/or flat surface structures, there will be no needto apply force using fasteners to conform the construction panel to thesurface structure.

As described above, in its compacted state, the pulverulent/particulatematerial 26 can include minute interstices between grains or particles.These interstices permit pressure-induced penetration of the uncuredpolymeric material, to a desired depth, at least partially due to thecompression that is applied to the jig or mold base 52 and/or the moldlid or cover 70. The pocket or receptacle 72 within the mold cover,which includes the sheathing panel substrate 14 at position 74, isthereby bound to the particulate material 26 and finish elements 24 bythe curing of the polymeric material. The sheathing substrate panel 14is thereby released from the pocket or receptacle 72 upon release of themold cover 70 from the mold base 52. The depth to which the uncuredliquid polymer penetrates into the interstices of the compactedparticulate material can be controlled by application of limited orcontrolled volume and/or mechanical pressure.

Thus, after the compaction operation, the polymer applicator mechanism68 can be activated to mix polymeric materials and distribute uncuredpolymer on the back portion 71 of the panel elements. Sufficientmaterial can be deposited into the mold to form the surround structure18 of the resulting panel. Compressive force then causes the polymericmaterial to enter the interstices between grains of particulatematerial, to bind the material in place and further distribute thematerial within spaces between the finish elements. Curing of thepolymeric material fixes the finish elements and particulate material inplace, and binds these elements to the sheathing panel.

Embodiments usable within the scope of the present disclosure can be atleast partially automated, thereby enabling enhanced volume ofmanufacture. For example, multiple conveying devices for simultaneousoperation of any and/or all steps in the panel manufacturing process canbe employed such that numerous panels may be simultaneously producedand/or can undergo various stages of production at the same time.

One suitable system for automated manufacture is shown schematically inFIG. 10, where mold bases 52 and/or other panel support and movementdevices can traverse an assembly line in a direction from left to right,as shown by movement arrows, along a mold conveyor 94 or similartransport means. In an embodiment, the mold conveyor can include aconveyor belt, a chain driven member, or any other type of device ableto cause incremental movement of a plurality of mold bases, and forpositioning the mold bases at various locations therealong (e.g.,production stations in an assembly line). As the mold bases 52 or otherpanel support devices are moved from one position to another by theconveyor 94, various manufacturing steps or operations can be performedsequentially at one or more positions.

While FIG. 10 shows a single linear conveyor 94, it should be understoodthat embodiments usable within the scope of the present disclosure caninclude any number and configuration of conveyors or other transportmeans able to move and/or position molds and/or panel components. Forexample, conveyors can transport components from supply areas tomanufacturing stations, and to other locations, as needed, to at leastpartially automate the manufacturing process.

To properly position and/or locate multiple finish elements in a spacedrelation within a mold base 52, a placement mechanism 96 can be used.The placement mechanism 96 shown in FIG. 10 includes an actuator 98usable to move the placement mechanism toward and away from the moldbases 52 (e.g., vertically) using an actuator mechanism 98. The positionof the finish elements within the placement mechanism 96 can determinethe location where the finish elements are deposited in the mold bases.Alternatively or additionally, the location of locator pins, ridges, ora jig within the mold base 52 can facilitate placement.

In one embodiment, the placement mechanism 96 can use mechanicalgripping members to retain and release finish elements. In anotherembodiment, the placement mechanism 96 can include one or more vacuumsupport devices usable to retain finish elements in associationtherewith. After the finish elements have been located with respect tothe mold base, the conveyor 94 can move the mold base into a desiredposition relative to a screed 100 and screed actuator mechanism 102. Thescreed can be moved by the actuator mechanism 102 into association withthe back faces of the finish elements to permit deposition ofparticulate material through the screed openings.

While FIG. 10 shows a planar screed member 100, it should be understoodthat particulate deposition members having any shape and/or dimensionscan be used, including a cylindrical screed member for rotary movementas the mold base and/or screed member move laterally relative to oneanother. The particulate material can be delivered by a feed andapplicator mechanism that extends to the screed member and deposits ameasured quantity of particulate through the openings thereof.

In an embodiment, a planar or rotary compaction mechanism 104, shownhaving open cell polymer or any other suitable deformable body 106 inassociation therewith, can be used to engage the back faces of thefinish elements to compact the particulate material within the spacesbetween finish elements. The deformable body 106 is shown mounted to apress plate 108 that can be moved by actuating shafts and/or posts 110.The deformable body 106, whether of planar or rotary character, canengage the panel elements and achieve compression or compaction ofparticulate material, while also retaining the finish elements in place.After the compaction operation has been completed the compactionmechanism can be raised to permit movement of the mold base, e.g., to asubsequent manufacturing station for application of polymeric foam.

A polymeric foam mixing and application system 112 for support andmovement of a polymeric foam mixing and applicator mechanism 68, isshown being supported and/or moved by an actuator mechanism having oneor more actuating posts 116, relative to a panel being manufactured. Thepolymeric foam mixing and applicator mechanism 68 can apply a contiguouslayer or substrate of polymeric foam thermal insulating and moistureproofing material to a panel, either during movement of the panel by theconveyor or during movement of the polymeric foam mixing and applicatormechanism 68, or during movement of both devices, as determined by thedesign of the panel manufacturing system.

After a polymeric substrate has been applied, and before the polymericmaterial cures, e.g., by the chemical reaction of its polymerconstituents, a backing or sheathing panel 14, carried by a mold closuremember 70, can be moved into surface-to-surface contact with the uncuredpolymeric material. FIG. 10 shows a sheathing panel positioningmechanism 120 having one or more support and actuation posts 122, towhich a sheathing panel support and positioning mechanism 124 ismounted. The sheathing panel support and positioning mechanism 124 isshown having a recess or pocket 125 within which the backing orsheathing panel 14 can be received. As described previously, the backingor sheathing panel 14 may be composed of any number of suitable panelmaterials, such as plywood, OSB, particle board, polymer, or anycombinations of these materials.

Backing or sheathing panels may be moved and/or retrieved from a supplyor storage site, such as by lateral movement of the backing or sheathingpanel positioning mechanism 120, and then positioned on the polymersubstrate. The backing or sheathing panel positioning mechanism 120 canbe actuated to apply a predetermined mechanical pressure to thesheathing panel 14, thereby subjecting the panel being manufactured to adesired compression pressure during curing of the polymeric material. Inan embodiment, a layer of release material, such as paper or a polymerfilm, can be positioned between the mold closure member 70 and thebacking or sheathing panel 14, to prevent uncured polymeric materialfrom contacting the mold closure member during compression.

Application of mechanical pressure to the panel can cause polymericmaterial to penetrate to a desired extent into the compacted particulatematerial, to become bonded with the finish elements, and to becomebonded to the backing or sheathing panel 14. This mechanical pressurecan also cause the polymeric material to have a density that enhancesthe structural integrity and water and air imperviousness of theresulting panel. The finished panels, thus manufactured, are then in theform of integrated panel substrate structures that will retain theirstructural integrity and provide many years of efficient service asstructural components, with a usable life as long or longer than that ofconventional masonry walls and other components of a building structure.The composite panels, due to the presence of the polymeric substrate,can provide efficient thermal insulation for a surface and can alsoserve as an efficient barrier to air infiltration and an efficientmoisture barrier to prevent intrusion of water.

In an embodiment, completed panels can be dusted and cleaned, subjectedto final inspection for quality control, and packaged. The size andlight weight of each panel can enable user friendly, easy installation.For example, an embodied panel can have a height of 4 feet and a widthof 19 and 3/16 inches, with a thickness of 1.5 inches; however, itshould be noted that other dimensions can be used, as desired. Userfriendly dimensions that enable easy manipulation and installation ofpanels can facilitate proper interlocking of adjacent panels and properinstallation over framework and/or other structural elements.

Additionally, embodied panels can be cut, e.g. using masonry cuttingblades, and could further be attached to sub-surfaces, e.g., usingscrews, adhesives, or other types of fasteners. Screws or similarfasteners can be placed in the spaces between finish elements (which, inan embodiment, can be spaced in a manner consistent with the 16″ or 24″on-center frequency of wall stud members in a conventional wallframework). Screw heads and adjacent panel joints can be treated withcaulking (e.g., clear silicone), and while such caulking materialremains uncured, particulate material can be applied to bond to thecaulk. Use of pliant and resilient caulk, can allow for expansion andcontraction of panel components while maintaining water resistance ofpanel joints. Any residual particulate material can be brushed or washedfrom the panel surface once caulking has cured.

Ends and edges of embodied panels can be manufactured for abuttingrelation with adjacent panels above, below and/or at the sides. Eachpanel end can be manufactured to interfit with an opposing end of anadjacent panel. This feature can allow for a constant and consistentblending of the finish materials of the panels. Corner installations canbe formed by fitting the ends of panels flush with the corner of thebuilding structure, and by filling any “missing brick” spaces in themanner described previously. In the event that a framework space is toosmall to receive a complete panel, panels may be cut to size, e.g.,using a masonry saw to avoid damage to the finish elements.

In an embodiment, all materials used in the manufacture and installationof embodied panels can be waterproof, and weather resistant, thusrequiring little or no maintenance. The mortar or brick cracking that istypically experienced during the service life of conventional brick andmortar wall installations will not typically be expected when usingembodied panels. Additionally, repair of embodied panels can beaccomplished quickly and easily, such as through replacement ofindividual surface-mounted finish elements, since unlike conventionalsurfaces, the finish elements are not structurally integral to thesurface. The embodied panels can also permit movement of components overtime, without resulting in the formation of cracks.

In addition to the construction of new walls and/or surfaces, embodiedpanels can also be applied over old siding, conventional sheathing,pre-fabricated panel systems, bare stud framework and, virtually in anyplace on any surface, in virtually any type of construction.

In one specific embodiment, the panel construction process can be nearlyentirely automated. For example, finish elements can be stored in astructure capable of containing numerous finish elements, arranged in amanner suitable for application to a completed panel. In an embodiment,such a structure can include a “magazine,” having orifices (e.g.,columns) within which multiple, stacked finish elements can be placed,resembling a three-dimensional jig.

Alternatively, the magazine could lack interior walls and/or separationmembers, and could simply include an external frame (e.g., a box) withinwhich stacks and/or columns of finish elements are arranged. The columnsof finish elements can be positioned such that the stacked finishelements are arranged in a manner corresponding to that of a finishedpanel (e.g., offset rows of thin brick elements having spacestherebetween for receiving particulate material). In a furtherembodiment, the “magazine” can include actuator and/or biasing membersat the base of one or more columns, for urging stacks of finish elementsupward for acquisition and use. For example, spring-biased rods/pistons,rods/platforms raised via a scissor lift, or other similaractuation/biasing members could be used. Alternatively or additionally,the entire floor of the magazine could be raised to position the finishelements within multiple columns at the upper surface thereof.

Independent of whether a magazine is used, or whether finish elementsare arranged manually or using other means, a set of arranged finishelements (e.g., each of the finish elements usable to produce a singlepanel, arranged in a manner corresponding to the arrangement of elementson the completed panel) can be simultaneously retained by a singleapparatus, such as a vacuum device, which can be used to lift and/orotherwise move the finish elements from the magazine or other storagearea. The vacuum can then be moved (e.g. laterally) to transport thefinish elements to a second step of the manufacturing process, oralternatively, the finish element storage can be moved and additionalapparatus for manufacturing panels can be moved into association withthe vacuum.

As such, after a set of arranged finish elements are bought intoassociation with a vacuum device, suction from the vacuum device canretain the finish elements such that the finish elements can occupy afirst portion of a vacuum frame, thus defining a first “zone” of thevacuum that is occupied by the finish elements, and a second “zone”defined by the spaces between the finish elements. While suction againstthe finish elements is maintained, the vacuum can be moved from themagazine into association with a particulate source (e.g., a tray and/orsimilar container having particulate matter therein), and/or themagazine and particulate source can be moved into association with thevacuum. Suction from the vacuum device can then cause the accumulationof particulate material in the spaces between finish elements (e.g., thesecond “zone” of the vacuum device), while the presence of the finishelements prevents accumulation of particulate material in the firstzone.

In an embodiment, the vacuum device can be used to retain one or moreframe members, e.g., about the edges thereof, before acquiring thefinish elements, after acquiring the finish elements, or after acquiringthe particulate material, as desired. The frame member(s) can define aborder that retains the particulate materials about the edge of theassembly.

Once the finish elements and particulate material (and the framemember(s), if applicable) have been retained by the vacuum device, thevacuum device can be placed in association with a mold, and suction fromthe vacuum device can be discontinued. The finish elements andparticulate material are thereby deposited within the mold in anarrangement suitable for immediate application of polymeric substratematerials and sheathing/backing, as described previously, therebysignificantly reducing the time required to position finish elements andparticulate material when compared to other manufacturing and assemblymethods. If frame members are also retained by the vacuum, the frame cansimilarly be deposited within and/or into association with the mold,such that the frame retains the edges of the panel components (e.g., theparticulate material) in a desired position during the molding process.Embodiments of the process described above can prepare a panel for themolding/compressing process in as little as one minute, or less.

FIGS. 13A and 13B show an embodiment of a finish element “magazine” 200usable within the scope of the present disclosure. Specifically, FIG.13A shows an isometric view of the magazine 200, while FIG. 13B shows adiagrammatic side sectional view thereof. The depicted embodimentincludes a rigid frame or body 202 (e.g., formed from wood, metal,plastic, composite, or similar generally durable materials), shownhaving a generally rectangular shape; however, it should be understoodthat a magazine having any shape and/or dimensions could be used, or inother embodiments, other apparatus or methods for storing and/orarranging finish elements could be used.

The interior of the magazine 200 can include a removable jig 204 and/orintegral/removable interior wall components, thereby dividing theinterior into a plurality of columns 206, each of which is sized tocontain a stack of finish elements 208. In other embodiments, internalspacing elements can be omitted, and the finish elements 208 can simplybe positioned in columns and/or stacks having a desired orientation. Atthe lower end of each column 206, a platform and/or similar supportmember 210 can be positioned, the platform 210 being movable upward anddownward within its respective column 206 using a scissor lift 212. Inother embodiments, the platform 210 could include a rod, piston, orsimilar elongate member.

Alternatively, platforms and/or support members could be omitted, andscissor lifts 212 or similar actuating and/or biasing apparatus couldcontact and move stacks of finish elements 208 directly. While FIG. 13Bdepicts scissor lifts 212 used to move the stacks of finish elements 208upward, it should be understood that the scissor lifts 212 are shown asa single exemplary embodiment, and that springs or other automaticbiasing members could be used, as could hydraulic, pneumatic, and/orother mechanical apparatus.

Additionally, while FIG. 13B depicts a plurality of platforms 210associated with respective columns in the magazine 200, in otherembodiments, a single platform beneath each column of finish elements208 could be raised, thereby lifting each stack of finish elements, andin an embodiment, any interior walls and/or jigs positioned within theinterior of the magazine 200. In other embodiments, a single platformcould include slots and/or orifices to accommodate the passage ofgenerally stationary interior walls.

During typical use, the platform(s) and associated actuating elementscan be used to raise each stack of finish elements 208, such that theuppermost finish elements in each stack are accessible to a vacuumapparatus. Once the uppermost finish elements are brought intoassociation with the vacuum apparatus and removed from the magazine, theplatform(s) and actuating elements can then lift each stack of finishelements to position the subsequent finish element of each stack at theupper surface of the magazine. In an embodiment, each column of stackedfinish elements can include approximately sixty individual finishelements, and a magazine can contain approximately 2500 finish elements,in sum.

FIGS. 14A, 14B, and 14C depict an embodiment of a frame 214, usable witha vacuum apparatus (not shown), e.g., to retrieve finish elements from amagazine, such as that shown in FIGS. 13A and 13B, or a similar storagearea, to retrieve particulate material within spaces between the finishelements, and to deposit the finish elements and particulate materialinto a mold or similar receptacle for subsequent manufacturing steps.

Specifically, FIG. 14A shows an isometric view of the frame 214, FIG.14B shows a top view, and FIG. 14C shows a diagrammatic side sectionalview thereof. The frame 214 can include various inlets and outlets (notshown), as known in the art, for accommodating connection to a vacuumapparatus and/or connections for engaging to a pulley system and/orsimilar apparatus for moving the frame 214.

The depicted frame 214 is shown having a generally rectangular shape(e.g., with four sidewalls and a top surface), the top surface havingmultiple element receiving regions 216 thereon. Each element receivingregion 216 can include a bore or orifice 218 therein, for engagementwith a vacuum apparatus and/or for transmitting suction from a vacuumapparatus therethrough. As such, suction provided by a vacuum apparatus,via the bores 218, will tend to draw finish elements to the elementreceiving regions 216. Between adjacent element receiving regions 216,and between the outermost element receiving regions 216 and the edges ofthe frame 214 are a plurality of slots 220.

Suction from a vacuum apparatus associated with the frame 214 can alsodraw material into and/or through the slots 220. In an embodiment, afirst vacuum apparatus can be provided in association with the bores 218in the element receiving regions 216, while a second vacuum apparatuscan be provided in association with the slots 220; however, it should beunderstood that a single vacuum apparatus can be used, the presence offinish elements within the frame 214 effectively defining multiple“zones” affected by the single vacuum apparatus, as described above andbelow.

FIG. 14B depicts the frame 214 having stand-off members 222 positionedover each of the element receiving regions 216, to effectively space anyoverlaying material from the bores 218. FIG. 14C depicts vacuum tubes224 associated with each element receiving region 216, for transmittingsuction from a vacuum apparatus to each region 216 via the bores 218(shown in FIGS. 14A and 14B). FIG. 14C further depicts a screen 226 orsimilar layer of overlaying material placed over the frame 214, andspaced from the bores 218 due to the presence of the stand-off members222. The screen 226 provides a generally smooth, flat, contiguoussurface for receiving finish elements and particulate material thereonwhen suction from a vacuum apparatus is applied therethrough.

FIGS. 15A through 15E illustrate a series of steps usable in oneembodiment of a method for manufacturing a panel using a vacuumapparatus to at least partially automate the transfer of finish elementsand particulate material from respective storage areas to a mold base.Specifically, FIG. 15A depicts a magazine 300 that can be of identicalor similar construction to the magazine shown in FIGS. 13A and 13B,positioned beneath a frame 302 adapted for association with a vacuumapparatus (not shown), such that suction from the vacuum apparatus canbe transmitted through the frame 302 to adhere panel components thereto,e.g., during panel assembly and transport of panel components to a mold.

The magazine 300 is shown having multiple columns and/or stacks 304 offinish elements therein, which can be arranged in a manner correspondingto the arrangement of finish elements on a completed panel, as describedpreviously, while the frame 302 is shown having an external surface 306(e.g., a screen or similar member) suitable for receiving panelcomponents during assembly and/or transport. In use, suction from thevacuum apparatus, applied through the frame 302, can draw the uppermostlayer of finish elements 308 to the surface 306.

Due to the arrangement of the finish elements 308 within the magazine300, the finish elements 308 are positioned on the surface 306 insubstantially the same arrangement, such an arrangement corresponding tothe arrangement of finish elements on a completed panel. The finishelements 308 can be drawn to defined regions of the frame 302, viaappropriate bores therein and/or or similar conduits/features forengagement with conduits of the vacuum apparatus, and in an embodiment,stand-off members for spacing the surface 306 from the body of the frame302, thereby defining a first vacuum zone, indicated by the arrow 310.

FIG. 15B depicts the frame 302 after the finish elements 308 have beenassociated with the surface 306 thereof using suction from an associatedvacuum device. The frame 302 is shown above a receptacle containingpanel border members 312. While in some embodiments, use of panel bordermembers 312 can be omitted, panel border members 312 can provide abarrier, e.g., about the perimeter of the panel components, to retainparticulate material within a defined region—specifically, so thatparticulate material captured by the vacuum apparatus does not extendbeyond the intended edge of the completed panel.

Use of the vacuum apparatus to removably retain panel border members 312against the surface 306 creates a transferable barrier, such that thepanel border members 312 can be deposited into a mold with the assembledpanel components to continue retaining the particulate material in adesired position until the molding process has been completed.Specifically, FIG. 15B illustrates suction through a second vacuum zonein the frame 302, represented by the arrows 314, usable to draw thepanel border members 312 to corresponding locations on the surface 306(e.g., proximate to the edge thereof, at a location corresponding to theedge of a completed panel).

While FIG. 15B depicts panel border members 312 intended to beassociated with a region of the surface 306 corresponding to theintended edges of a completed panel, in various embodiments, bordermembers could be associated with portions of the surface 306corresponding to interior portions of the completed panel, depending onthe intended configuration thereof. Additionally, it should beunderstood that while reference to distinct vacuum zones 310, 314 ismade, and that multiple vacuum apparatus (e.g., one vacuum apparatus perzone) could be separately actuated during respective steps of theassembly and manufacturing process, in an embodiment, a single vacuumapparatus can be used.

For example, the presence of the finish elements 308 on the surface 306prevents suction from the vacuum apparatus from passing through occupiedportions of the surface 306, such that subsequent materials willgenerally only be drawn to other, unoccupied regions of the surface 306.As such, the presence of the finish elements 308 effectively creates asecond vacuum zone, even though a single vacuum apparatus could be usedto apply suction through the entirety of the surface 306.

FIG. 15C depicts the frame 302 after both the finish elements 308 andpanel border members 312 have been associated with the surface 306thereof using suction from an associated vacuum device. The frame 302 isshown above a receptacle 316 containing particulate material 318. Use ofan associated vacuum apparatus to apply suction through the frame 302,specifically, a third vacuum zone thereof, represented by the arrow 320,thereby draws particulate material 318 to regions between the finishelements 308, and between the outermost finish elements and the panelborder members 312. As described above, the third vacuum zone 320 can bedefined by the presence of the finish elements 308 and panel bordermembers 312, which prevent suction, from the vacuum apparatus, fromdrawing particulate material to portions of the surface 306 that areoccupied by the finish elements 308 and border members 312.

As discussed previously, while reference is made to a third vacuum zone320, each of the vacuum zones 310, 314, 320 could have suction appliedthereto using separate apparatus, a single apparatus capable of applyingsuction to discrete portions of the frame 302, or a single apparatusthat applies suction through the entirety of the surface 306 while thepresence of panel components thereon creates effective vacuum zones bypreventing the vacuum apparatus from associating additional componentswith portions of the surface 306 that are occupied and/or obstructed.

While FIGS. 15A through 15C illustrate the panel border members 312being associated with the frame 302 after association of the finishelements 308 and before association of the particulate material 318therewith, it should be understood that the above steps could beperformed in various sequences without departing from the scope of thepresent disclosure. For example, the panel border members 312 could beassociated with the frame 302 before any panel elements (e.g., thefinish elements 308 and/or the particulate material 318) are associatedtherewith, or alternatively, the panel border members 312 could beassociated with the frame 302 after associating the frame 302 with boththe finish elements 308 and particulate material 318, such that theborder members 312 displace excess particulate material to define theintended edge of a completed panel. Panel border members 312 could alsobe associated with the frame 302 after association of the finishelements 308 therewith, and before association of the particulatematerial 318, as described above.

FIG. 15D depicts the frame 302 after association of the finish elements308, panel border members 312, and particulate material 318 therewith.When the processes illustrated in FIGS. 15A through 15C and describedabove and performed, the panel elements 308, 318 are arranged on thesurface 306 in a manner corresponding to that of a finished panel. Assuch, FIG. 15D depicts the frame 302, the associated panel elements 308,318, and the panel border members 312 positioned above a mold base 322,such that the frame 302 can be lowered and/or otherwise positioned inassociation with the mold base 322 to deposit the panel elements 308,318 and border members 312 therein, in substantially the sameorientation.

FIG. 15E depicts the mold base 322 after suction from the vacuumapparatus has been ceased, thereby causing the finish elements 308,particulate material 318, and panel border members 312 to be depositedinto the mold base 322 in an orientation corresponding to that in whichthe finish elements 308, particulate material 318, and border members312 were retained on the frame 302 (shown in FIGS. 15A through 15D), andto that of a completed panel. After depositing the finish elements 308,particulate material 318, and panel border members 312 within the moldbase 322, subsequent manufacturing steps (e.g., the application of apolymeric substrate material and a sheathing/backing layer, and use ofcompression) can be performed in the manner described previously.

As such, uncured polymeric material can be permitted to penetrate intothe particulate material 318 to form a secure bond between each of thepanel elements as it cures, while the panel border members 312 preventmovement of the particulate material 318 beyond the intended edge of thecompleted panel prior to the curing of the polymeric substrate. Afterthe molding process has been completed, the panel border members 312 canbe removed.

FIG. 11 is a vertical sectional view illustrating a conventional brickveneer wall structure of a building, shown generally at 130,representing the prior art. The wall structure 130, as illustrated bythe sectional view, incorporates a wall framework 132 that is shown tobe supported by a foundation 134. The wall framework 132 incorporatesstud members 133, sill members 135, and cap members 137. It should benoted that the foundation 134 for the brick veneer wall of FIG. 11 mustextend outwardly beyond the wall framework 132 to provide a supportledge 136 for the brick and mortar veneer wall material 138. Sheathingpanel material 140 is fixed to the framework 132 to provide for thermalinsulation and to provide a moisture barrier.

During current construction practices, the sheathing panel joints,between sheathing panels, are not typically sealed in any manner, so inhumid regions, moisture can penetrate the sheathing to a sufficientextent to be potentially damaging to the typically wood wall framework.Also, the conventional brick veneer wall structure 130 typically definesan air gap or vent 142 between the interior surface of the brick veneerwall 138 and the insulation and moisture resistant sheathing panels thatare fixed to the exterior of the framework. Additionally, theconventional brick veneer wall employs mechanical tie members 144 toprovide the brick and mortar wall with lateral support by the buildingframework.

In comparison with the brick veneer wall structure of FIG. 11, thevertical sectional view of FIG. 12 shows a wall structure generally at150 that is constructed in accordance with one or more embodimentsusable within the scope of the present disclosure. The exterior wallstructure 150 is shown associated with a conventional wall framework132, having framework components that are essentially the same asdescribed in connection with FIG. 11. The wall framework 132 issupported by a foundation 154 that can be of less expensive constructionas compared with the foundation of FIG. 11 in that it does not include abrick support ledge.

The foundation 154 can be slightly smaller, as compared with thefoundation 134 of FIG. 11, because it does not need to extendsignificantly beyond the outer limits of the building framework 132. Thefoundation 154 can be designed to support less weight as compared withthe foundation 134 of FIG. 11, because it need not be designed tosupport the weight of a conventional brick and mortar wall, thus furtherminimizing the cost of the foundation. The resulting wall constructionof FIG. 12 can be much thinner than the thickness of a conventionalbrick veneer wall and can be of significantly less weight, thusproviding for significant cost savings without detracting from thedurability and longevity of the wall.

Embodied panels 10 can be fixed to the wall framework 132 by means offasteners, such as screws or adhesive, can provide thermal insulationcharacteristics, can serve as structural enhancement for the frameworkstructure of the wall, and can provide a moisture and air barrier.Fasteners that penetrate the panels can be located in the spaces betweenfinish elements, and engage within the wall studs or other structuralmembers of the wall framework 132. If desired, the panels 10 may beapplied over existing wall materials, such as the conventional sheathing140 of FIG. 11.

The panels, as discussed in detail above, can support thin brick orother facade members 24 which define the outer surface of the completedcomposite paneled wall 150. Significant savings in time, labor andmaterials can thereby be gained through employment of the presentinvention. The resulting completed wall construction can withstand equalor greater wind loads as compared with that of a conventional brickveneer wall. Moreover, as building settling and thermal movement occursover time, conventional brick veneer walls tend to crack and must berepaired. Embodiments of the preset panels can have significantflexibility, sufficient to flex when building structure movement occurs,without developing significant cracks.

While various embodiments of the present invention have been describedwith emphasis, it should be understood that within the scope of theappended claims, the present invention might be practiced other than asspecifically described herein.

What is claimed is:
 1. A composite panel usable for forming a surface,the panel comprising: an at least one finish element; a backingmaterial, the backing material configured to provide the panel with areduced thickness, a reduced weight, or combinations thereof; and apolyurethane material cured between the at least one finish element andthe backing material, wherein upon curing, the polyurethane materialforms a structural substrate having a first side and a second side,wherein upon curing, the backing material is adhesively bonded to thefirst side, and wherein upon the curing, the at least one finish elementis adhesively bonded to the second side.
 2. The composite panel of claim1, the panel further comprising a particulate material disposedproximate to the first side of the structural substrate, and between afirst finish element and a second element, wherein the structuresubstrate material bonds the particulate material to said at least onefinish element and the backing material.
 3. The composite panel of claim2, wherein the layer of substrate material at least partially occupiesinterstices between particles of the particulate material.
 4. Thecomposite panel of claim 3, wherein the particulate material comprises abinder composition.
 5. The composite panel of claim 1, wherein the atleast one finish element comprises magnesium oxide, and wherein the atleast one finish element is configured to further provide the panel witha reduced thickness, a reduced weight, or combinations thereof.
 6. Thecomposite panel of claim 1, wherein the at least one finish elementcomprises a body having an interior surface bonded to the structuralsubstrate, and wherein the at least one finish element comprises and anexterior surface has a coating comprising cement, clay, and anaggregate, and wherein the coating provides said at least one finishelement with an appearance of a natural clay brick.
 7. The compositepanel of claim 6, wherein the clay comprises clay dust, and wherein theaggregate comprises sand.
 8. The composite panel of claim 1, wherein thepanel is configured for installation on at least one of an exterior wallof a building, an interior wall of a building, a floor, a ceiling, aroof, a counter, a backsplash, and combinations thereof.
 9. A compositepanel usable for forming a surface, the panel comprising: a first finishelement and a second finish element; a backing material; a curedpolyurethane material having a first side and a second side, the curedpolyurethane material being cured between the first finish element andthe backing material; and a particulate material disposed proximate tothe first side, and between the first finish element and the secondfinish element; wherein the backing material is adhesively bonded to thefirst side, and wherein the first finish element is adhesively bonded tothe second side.
 10. The composite panel of claim 9, wherein the curedpolyurethane material bonds the particulate material to the first finishelement.
 11. The composite panel of claim 10, wherein the curedpolyurethane material at least partially occupies interstices betweenparticles of the particulate material.
 12. The composite panel of claim11, wherein the particulate material comprises a binder composition. 13.The composite panel of claim 12, wherein at least one of the firstfinish element and the second finish element comprises magnesium oxide,and wherein at least one of the first finish element and the secondfinish element is configured to further provide the panel with a reducedthickness, a reduced weight, or combinations thereof.
 14. The compositepanel of claim 13, wherein the first finish element comprises a bodyhaving an interior surface bonded to the structural substrate, andwherein the first finish element comprises and an exterior surface has acoating comprising cement, clay, and an aggregate, and wherein thecoating provides said at least one finish element with an appearance ofa natural clay brick.
 15. The composite panel of claim 14, wherein theclay comprises clay dust, and wherein the aggregate comprises sand. 16.The composite panel of claim 15, wherein the composite panel isconfigured for installation on at least one of an exterior wall of abuilding, an interior wall of a building, a floor, a ceiling, a roof, acounter, a backsplash, and combinations thereof.